Dry wall extrusion grille frame

ABSTRACT

A one piece dry wall extrusion grille frame comprising: a frame; pre-drilled installation holes in said frame; a lip for plastering; grille or register; capture recesses for plaster; and no additional hardware for drop in installation.

FIELD OF THE INVENTION

The present invention relates to a one piece dry wall extrusion grille frame needing no additional hardware for drop in installation, comprising pre-drilled installation holes, a lip for plastering, and capture recesses for plaster. The grille frame mounts flush to the wall.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 5,082,083 relates to a structure wall mounted speaker assembly. The woofer of the speaker is mounted in the assembly wall frame and the tweeter is both mounted in and self-contained within the assembly wall frame. The installation requires only that a circular opening be cut in the wall to enable the rear portion of the woofer to extend through the dry wall or sheetrock and two simple holes drilled in the wall to accommodate the support bolts to retain the wall mounted speaker assembly on the wall.

U.S. Pat. No. 7,140,960 relates to duct systems, registers and ductwork components used with floor or ceiling registers employed in warm air heating, ventilating and air conditioning systems, and improvements for mounting and installing components of the duct system, including register boots, mud rings and register grilles, in the walls, floors or ceilings of buildings components, mud ring, register grille and wall, floor or ceiling opening, which reduces costs.

U.S. Pat. No. 7,771,259 relates to a flush mounted frame for an access panel or register. The frame is mounted to a wall, ceiling or floor surface, and is made by joining linear frame sections each providing interconnected elements formed by an extrusion process. A first planar element is spaced apart from a second planar element and positioned for abutting a common surface. A first channel element is formed between the first and second planar elements. A third planar element is positioned normal to the first and second planar elements and terminates with a rib directed toward the first planar element. When mounted onto studs in a building structure, wall putty or mud may be placed into a space between the wall panels and the third planar element, the mud is captured in place forming a smooth interface between the frame assembly and the surrounding wall surfaces.

The prior art relies on corner keys, locks to create a frame and extra components. The prior art does not have a flexible mounting flange. The prior art requires attachment to a structural member, stud or beam, and therefore a skilled installer is needed to install the prior art grille frame.

The prior art requires multiple planar extensions and complexities requiring more costly material/extrusions. With the prior art, one cannot create a radius or curved frame.

SUMMARY OF THE INVENTION

The present invention relates to a one piece dry wall extrusion grille frame. The dry wall extrusion grille frame needs no additional hardware for drop in installation. The dry wall extrusion grille frame comprises pre-drilled installation holes, a lip for plastering, and capture recesses for plaster. The grille frame mounts flush to the wall.

It is an object of the present invention for the dry wall extrusion grille frame to comprise a structure constructed of four extrusions welded together to create a strong, single piece frame. It is an object of the present invention for the frame to comprise multiple, pre-punched holes. It is an object of the present invention for the frame to comprise a flexible mounting flange.

It is an object of the present invention for the flexible mounting flange to enable an installer with basic skills to position the frame at a wall, floor, ceiling, duct or ventilation opening.

It is an object of the present invention for the flexible mounting flange to contain multiple recesses to capture mud, plaster, or wallboard compound.

It is an object of the present invention for the grille frame to comprise a projection that is perpendicular to the mounting flange for providing an installer with a natural guide for a wallboard compound, plaster or mud knife to simplify application of plaster, mud or spackle compound.

It is an object of the present invention for the dry wall extrusion grille frame to not require fixturing or attachment to a structural building element, wall stud or support beam. This eliminates the need for the installer to locate the position and spacing of a structural element, wall stud or support beam, greatly reducing installation time and labor costs and the skill level of an installer.

It is an object of the present invention for the frame to comprise numerous pre-punched holes through which standard securing devices secure the unit to a wall, floor or ceiling. It is an object of the present invention for the securing devices to comprise standard wall board screws. It is an object of the present invention for the frame to alternatively be attached with construction adhesive or silicone.

It is an object of the present invention for the frame to include a projection that goes into an opening providing stability and a mounting point for a damper or filter.

It is an object of the present invention for the frame to mount flush so that a perforated metal, wood or plastic grille or register attached to the frame is also flush to the wall.

It is an object of the present invention to comprise a flange large enough to provide left to right and top to bottom positioning adjustability to an installer, saving time and the need to precision cut the opening.

It is an object of the present invention for the grille frame to further comprise an L shaped extruded projection that provides strength while embodying a mounting flange, frame structure, and the ability to customize fastening points.

It is an object of the present invention for the L shaped frame to comprise welded projections or tabs for attaching perforated metal, plastic, and wood registers and grilles to the grille frame. This provides total customization for the number and placement of the grille/register mounting screw locations while insuring there is minimal interference with air flow.

It is an object of the present invention for the frame design to include a projection as part of the extrusion should air flow not be a concern.

It is an object of the present invention for the frame to be constructed of four extrusion lengths, which can be cut to any length, and welded at the corners to create a strong, one piece structure in a square, rectangular or radius shape.

It is an object of the present invention for the dry wall extrusion grille frame to comprise a frame, a grille or register, sheet rock screws, pre-perforated through holes, indented slots, a flexible edge.

It is an object of the present invention for the indented slots to capture joint compound or plaster.

It is an object of the present invention for the flexible edge to be used for fastening to a wall or ceiling with pre-perforated through holes.

It is an object of the present invention for a common sheet rock or wall board screws to be threaded into the wall material.

It is an object of the present invention for the frame to be installed with standard sheet rock or wall board screws before plaster or a joint compound is applied.

It is an object of the present invention for the dry wall extrusion grille frame to be installed to a wall with four sheet rock or wall board screws.

It is an object of the present invention for the extrusion grille frame to have pre-punched mounting through holes providing many mounting options to address multiple wall, floor or ceiling conditions.

It is an object of the present invention for the extrusion grille frame to be a fully welded construction that provides exceptional strength for mounting in walls, floors and ceilings

It is an object of the present invention for the extrusion grille frame to have multiple, pre-punched mounting holes for fastening in a wide range of wall and ceiling conditions and materials

It is an object of the present invention for the extrusion grille frame to have pre-punched holes accurately sized for standard wall board/sheet rock screws so no special hardware or tools are required.

It is an object of the present invention for the extrusion grille frame to have multiple indented slots along the mounting flange to provide capture points for joint compound or plaster.

It is an object of the present invention for the extrusion grille frame to comprise flexible mounting flange that fasten the grille to uneven wall surfaces.

It is an object of the present invention to have unlimited shape possibilities for the frame, including but not limited to radius, square, rectangular, angular, round and triangular.

It is an object of the present invention for the inside of the extrusion grille frame to extend a minimum of ⅝″ deep into the opening so that the extrusion grille frame is installed in a wall board or plaster ranging from about ¼″ thru about ¾″ thick.

It is an object of the present invention for the extrusion grille frame to allow an installer to cut a very rough hole or opening in a wall or ceiling and slip the extrusion grille frame into the opening. It is an object of the present invention for there to be no routing or recessed cut that is necessary. It is an object of the present invention for there to be no blocking or added wood supports necessary for attachment to a wall or ceiling.

It is an object of the present invention for the extrusion grille frame to combine the exceptional strength and light weight characteristics of aluminum material—thus enabling safe use in ceiling applications.

It is an object of the present invention for the extrusion grille frame to be mounted, so that the entire frame and grille are flush to the wall providing a seamless installation—which makes field painting much easier—also makes future cleaning of the grille simpler as can be done with simply the wipe of a rag

It is an object of the present invention for the extrusion grille frame to be mounted in only one way, so that it cannot be installed backward.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a view of the frame of the present invention to be welded together.

FIG. 2 shows a view of the frame of the present invention that is welded together.

FIG. 3 shows a view of the frame of the present invention to be welded together.

FIG. 4 shows a view of the frame of the present invention that is welded together.

FIG. 5 is a cross sectional view of the extrusion grille frame of the present invention.

FIG. 6 shows a solid projection of the extrusion grille frame of FIG. 5 as a solid piece.

FIG. 7 shows a welded projection of the extrusion grille frame of FIG. 5 as a welded piece.

FIG. 8 is a front view of an extrusion grille frame of the present invention.

FIG. 9 is a front view of an extrusion grille frame of the present invention.

FIG. 10 is a front view of an extrusion grille frame of the present invention.

FIG. 11 is a cross-sectional view through section A-A of FIG. 10.

FIG. 12 is a cross-sectional view through section B-B of FIG. 10.

FIG. 13 is an enlarged view of section C of FIG. 11.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows the frame 10 comprising four mitered pieces 12, 14, 16 and 18, which are welded at 20, 22, 24, and 26. The frame has a flexible mounting flange 28, and multiple pre-punched holes 30. FIG. 2 shows the frame 10 of FIG. 1 welded together.

FIG. 3 shows the frame 40 comprising four mitered pieces 42, 44, 46 and 48, which are welded at 50, 52, 54, and 56. The frame has flexible mounting flange 58, and multiple pre-punched holes 60. FIG. 4 shows the frame 40 of FIG. 3 welded together.

FIG. 5 shows the grille or register 100, mounted to the dry wall extrusion grille frame which is mudded or plastered, flushed with the wall. The extrusion grille frame further comprises multiple recesses 104 used to capture joint compound, mud or plaster 102, and projections 106 and 110 that provides a projection for a spackle knife to rest on. The projection 106 can be made as one piece as shown in FIG. 6 or be a welded projection 110 as shown in FIG. 7. The projections 120 can be where the grille or register 100 is mounted. As shown in FIG. 5, the projections 120 creates a flush mount for the grille or register 100. The projection 106 projects into an opening shown in FIG. 5. Common sheet rock screw 112 and 114 are threaded into the wall material.

FIGS. 8-10 show the grille frame 140 having multiple pre-punched holes 142, and a large mounting flange 144. The grille frame 140 is flush mounted 146.

FIG. 11 is a cross-sectional view through section A-A of FIG. 10.

FIG. 12 is a cross-sectional view through section B-B of FIG. 10.

FIG. 13 is an enlarged view of section C of FIG. 11. 

1. A one piece dry wall extrusion grille frame comprising: a frame; pre-drilled or pre-punched installation holes in said frame; a lip for plastering; grille or register; capture recesses for plaster; no additional hardware for drop in installation.
 2. The dry wall extrusion grille frame of claim 1 wherein said frame mounts flush to a wall.
 3. The dry wall extrusion grille frame of claim 1 wherein said frame is constructed of four extensions welded together to create a single piece frame.
 4. The dry wall extrusion grille frame of claim 1 wherein said frame comprises a flexible mounting flange.
 5. The dry wall extrusion grille frame of claim 4 wherein said flexible mounting flange enables an installer to position said frame at a wall, floor, ceiling, duct or ventilation opening.
 6. The dry wall extrusion grille frame of claim 4 wherein said flexible mounting flange contains multiple recesses to capture mud, plaster, or wallboard compound.
 7. The dry wall extrusion grille frame of claim 4 further comprising a projection that is perpendicular to said mounting flange for providing an installer with a natural guide for a wallboard compound, plaster or mud knife to apply plaster, mud or spackle compound.
 8. The dry wall extrusion grille frame of claim 7 wherein said projection is a single solid piece.
 9. The dry wall extrusion grille frame of claim 7 wherein said projection is a welded projection.
 10. The dry wall extrusion grille frame of claim 7 wherein said projection creates a flush mount for said frame.
 11. The dry wall extrusion grille frame of claim 1 wherein said frame does not require fixturing or attachment to a structural building element, wall stud or support beam.
 12. The dry wall extrusion grille frame of claim 1 wherein said frame uses standard securing devices for said pre-drilled holes to secure said frame to a wall, floor or ceiling.
 13. The dry wall extrusion grille frame of claim 12 wherein said frame is secured by wall board screws, construction adhesive or silicone.
 14. The dry wall extrusion grille frame of claim 1 wherein said frame further comprises a projection that goes into an opening providing stability and a mounting point for a damper or filter.
 15. The dry wall extrusion grille frame of claim 1 wherein said frame is mounted flush to a wall so that a perforated metal, wood or plastic grille or register attached to said frame is also flush mounted to said wall.
 16. The dry wall extrusion grille frame of claim 4 wherein said flange is large enough to provide left to right and top to bottom positioning adjustability.
 17. The dry wall extrusion grille frame of claim 1 further comprising an L shaped extrusion projection that comprises a mounting flange, frame structure, and provides customized fastening points.
 18. The dry wall extrusion grille frame of claim 17 wherein said L shaped frame has welded projections or tabs for attaching perforated metal, plastic, or wood registers and grilles to said grille frame.
 19. The dry wall extrusion grille frame of claim 18 wherein number and placement of mounting screws insures minimal interference air flow.
 20. The dry wall extrusion grille frame of claim 1 further comprising a mounting flange.
 21. The dry wall extrusion grille frame of claim 1 wherein said grille frames has unlimited shape possibilities including radius, square, rectangular, angular, round and triangular.
 22. The dry wall extrusion grille frame of claim 1 wherein said grille frame extends a minimum of ⅝″ deep. 